Method of building walls and floors



Dec. 31, 1940. c. R. PAYNE 2,227,228

METHOD OF BUILDING WALLS AND FLOORS Filed June 5, 1939 x, m, I

Patented Dec. 31, 1940 2,227,222 v METHOD OF BUILDING WALLS AND moons Claron R. Payne, Allentown, Pa.,

assignor to The Atlas Mineral Products Company, Mertztown,

Pa., afcorporation of Pennsylvania Application June 5, 193a Serial No. 277,538 9 Claims. (Cia 72-44) This invention relates to an improved method for the construction of Walls and floors for use particularly'for tanks for pickling purposes but 1 also of equal value in construction of chemical 6 equipment, fume ducts, stacks, etc.

The building of tanks for these purposes requires the exercise of care in order that the walls and floors may be capable of withstanding the pressures to which they will be subjected, will be 10 proof against leakage, will be capable of resisting tcrtion-al strains and thermal stresses incident to variations in temperatures of the contents, and

, will be acid resistant.

It is the purpose of the present invention .to provide a method in the-construction of walls and floors for pickling tanks capable of meeting these several requirements, enabling the tank to be constructed at less expense than has heretofore been necessary and, additionally, enabling the tank to be put in operation much more quickly than has heretofore been found possible with other structures seeking to accomplish the same general purposes.

These objects, as well as others that will appear 25 as the description proceeds, are accomplished by I the method hereinafter set forth in detailand specifically claimed, reference being had to the drawing, wherein:

Figure l is a transverse sectional view taken through a part of a floor and wall erected or C011? structed in accordance with the improved method,

Figure 21s a fragmentary sectional view showing a wall erected in accordance with the invention but involving a slight variation in the elements employed,

Figure 3 is a similar view showing a further variation, and f Figure 4 is a similar view showing a still further modification.

jIanks of this general character include a bottom and side supporting structure 5 which may be of steel, concrete, wood or any other material,

erected in such manner as to be capable of with 5. standing the weights and pressures to which the enclosed tank will be subjected 1 lreparatory. .to the erection of the tank lining and flooring courses it is customary to face the walls and floor of the supporting structure 5 with a leak'proof impervious coating 6. This'coating may be of a proper or desired plastic or elastic substance firmly secured to the bottom and walls of the supporting structure, and may vary in thickness, plasticity or elasticity in accordance with requirements of the particular tank. The

' ments of the particular tank.

materials ofwhich this coating is made may extend through a wide range of substances, and may be applied hot or cold, in sheet form or cold dissolved or dispersed in a solvent as a mortar or in a molten state "by spraying or brushing '5 processes. v

Arranged upon the floor of the supporting structure and around the sides thereof and spaced a proper distance therefrom is a course of building units such as bricks or blocks it, These blocks 10 are spaced from each other, and from the bottom by the spacing elements or chips 1, as well as from the side of the supporting structure as shown, so as to provide spaces, channels or voids t for the application of impervious bonding ma- 15 terial. The blocks of this course are made of acid proof material, and may be vitrified clay or shale or may be rnade of carbon or similar acid proof and acid resistant materials.

The liner per se for the tank is indicated at Hi, 20 and consists of a course of acid proof bricks or blocks laid relatively close together upon the floor and around the sides of the tank but spaced from the course 8. The blocks or bricks constituting the course It may be of material similar 25 to that of which the course 8 is" formed, or may vary in accordance with the needs or require- The blocks it are rigidly secured together and have their joints sealed with a temperature resistant cement or'ao chemical reaction, or is set or hardened by an increase in temperature, or whose set is accelerated by both chemical reaction and an in- 35 crease in temperature.

As the courses 8 and it are laid, the voids or spaces 9 surrounding the blocks or the inner structure are filled with a cement-or bonding material or substance 9 applied bymelting and 4 pouring. The substance or material of which the coating 8 is formed shall be such as not to be injuriously affected by the temperature of the hot mixture constituting the bonding agent, and by applying a hot bonding agent behind the course 5 or liner I U, acceleration of set or hardening of the bonding materials of the course ill by the heat given off during solidification of the molten substance is obtained, The cements or jointing ess is slow, and those parts of the cement exposed to atmosphere or to the inner face of the tank will first become set, thus trapping the moisture or gases. By the application of heat to the rear face of the course, however, moisture or gases are driven outwardly toward the surface and the setting becomes rapid and uniform.

course ID with the impervious bonding material surrounding the blocks of the course 8, produces a liquid tight wall or floor which will withstand temperatures within the, tank above that for which the bonding. material of the course 8 is satisfactory. The molten material constituting the bonding agent for the inner course has a coeflicient of expansion considerably higher than has the cement securing the blocks of the liner Ill, and owing to the rapid temperature drop through the brick wall l0, advantage can be taken of these differences in coefficient of expansion to reduce thermal stresses in the brick lining over those which would exist if the same jointing material were used in both courses. Similarly, the blocks of the course In may have a. coefficient of expansion less than the blocks used in the course 8.

The coating 6,, as has been before mentioned, is a plastic orelastic'substance firmly adhered to the face of the supporting structure and serves as the final seal against any seepage of acid through the brick lining. The brick courseshero employed furnish proper insulation and protection to the coating against excessive temperatures, abrasion, and mechanical punishment which may prevail in the tank.

In Figure 2 of the drawing, the structure is identical with that shown in Figure 1 except that the coating is omitted from the inner face of the supporting structure 5. If the substance of the bonding agent employed in connection with the course 8 is sufficiently plastic, as well as possessing the characteristics above described, the coating for the inner face of the supporting structure may be omitted.

Figure 3 illustrates a further variation and wherein a double course of blocks or bricks 8 are employed to obtain a higher degree of insulation and protection against leakage, while in Figure 4 a single course of blocks 8 is shown with double courses of bricks or blocks In which constitute the liner per se. These variations are optional, according to the needs or requirements of the particular tank.

I am aware that the invention may be successfully practiced with a wide variety of materials and compositions, and the following examples are given as illustrative only and not as limiting or restricting:

For the coating 6.-A plastic or elastic substance such as rubber, soft or hard or a combination of both, polymerized vinyl chloride resins, Bakelite resin coatings or asphalts or compounds thereof having required physical and chemical properties for the particular application.

For the reinforcing layers 8 and 10.Bricks or blocks of acid proof materials, such as vitrified clay or shale or of carbon, etc.

For bonding agent 9.A hot pour cement such as sulphur, asphaltic or bitumin0us,'capable of withstanding temperatures approximately For bonding agent for wall section 10.Phenol formaldehyde, or sodium silicate cements, being acid proof and capable of withstanding excessive temperatures.

In constructing the walls and floors of the tank in accordance with this method, efiective insulation and acid resistant functions are secured. The variation in the coeflicient of expansion between. the courses as set forth is availed of to reduce thermal stresses in the brick lining to a minimum. By the application of a hot bonding agent behind that course of bricks or blobks which constitutes the liner per se, the bonding agent of the latter becomes rapidly set and the tank may therefore be placed in service almost immediately after its completion.

In this description and in the claims, reference is made to the structure as a wall," and it will be understood that the method is not confined to a wall structure in its limited meaning but is meant to include floor structures as well.

Having thus described my invention, what I claim as new and useful is:

1. The method of building a wall which consists in assembling a plurality of building units and securing the same together with a bonding material whose set is accelerated by an increase in. temperature, backing said units with a structure of reinforcing elements, and applying a bonding agent to said elements to secure the same together and at a temperature sufiicient to accelerate the set of said bonding material.

2. The method of building a wall which consists in arranging a plurality of building units between complemental structures, one of which at least includes a bonding material whose set is accelerated by an increase of temperature, and applying a hot bonding agent to said units.

3. The method of building a wall which consists in laying a course of building units and securing the same together with a bonding agent having the properties of giving off moisture and gas during the setting period and whose set is accelerated by heat, backing said course with a reinforcing course whose units are spaced from each other and from said first course, and filling the voids of said reinforcing course with a hot bonding agent.

4. The method of building a wall which consists in erecting a supporting structure, laying a course of units adjacent to but spaced from each other and from said structure, laying a lining structure course adjacent to but spaced from the first named course, securing the units of the lining structure together with a bonding material having properties of giving ofi moisture and gas in the setting period and whose set is accelerated by heat, and pouring a hot bonding agent in the spaces between the units of said first named course and between the latter and the supporting structure and the lining course.

5. The method of building a wall which consists in erecting a supporting wall, coating said wall with insulating mate'ial of plastic consistency, erecting a course of building units adjacent to but spaced from said wall, erecting a lining wall adjacent to said course, and filling the voids between said units and said supporting wall with a hot bonding agent.

6. The method of building a wall which consists in erecting a supporting structure, coating said structure with rubber, laying a course of units adjacent to but spaced from each other and from said supporting structure, erecting a liner adjacent to but spaced from said course, securing the units of said liner with a bonding agent Whose set is accelerated by heat, and filling the voids between said course of units, said liner and said supporting bonding agent.

7. The method of building a wall which consists in erecting a supporting structure and coating the same with an impervious layer, laying a course of units adjacent to but spaced from said structure, securing said units together with a bonding agent whose set is accelerated by an increase in temperature, and filling the spaces between said units and said supporting structure with a hot bonding agent.

8. The method of building a wall which con structure with a hot sists in erecting a supporting structure, coating said structure with an insulating material of plastic consistency, erecting a course of building units adjacent to but spaced from said structure and from each other. erecting a lining wall adjacent to but spaced from said course, securing the units of said lining wall with a bonding material whose set is accelerated by heat, and filling the spaces between said supporting structure and said course and between said course and said lining wall with a hot bonding agent.

9. The method of building ,a wall which consists in erecting a wall section with a bonding material whose set is accelerated by an increase in temperature, and applying a reinforcing element including a bonding agent against a surface of said wall section and at a temperature suflicient to accelerate the set of said bonding material.

CLARON R. PAYNE. 

